Engine

Engine Model:

General Motors 3.0 L PowertrainEPA Certified Engines

Generator Models:

25/30REZG

TP-6742 4/10

Service Parts

Table of ContentsDescription Page

Introduction 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Number System Significance 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Illustrations 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

How to Find Part Numbers 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hardware References 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1--2: Starter 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1--3: Fan Spacer 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1--5: Flywheel Adapter 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1--6: Flywheel/Housing 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1--7: Exhaust/Intake Manifold 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1--11: Electrical 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1--13: Fuel System 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1--14: Dress Kit 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1--15: Alternator 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2--1: Engine Block/Lower End 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2--2: Engine Head/Upper End 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3TP-6742 4/10

Introduction

This manual lists service replacement parts for General

Motors 3.0L engines.

Information in this publication represents data available

at the time of print. Kohler Co. reserves the right to

change this publication and the products represented

without notice and without any obligation or liability

whatsoever.

This manual includes the following main sections:

Table of Contents. Lists the sections of the manual.

Introduction (and other information sections).

Contains introductory material about part numbers,

illustrations, and hardware.

Group Parts Lists. List the part numbers of parts in the

groups.

Numbering System SignificanceThis manual uses the following numbering systems:

Group Number. A unique number representing a parts

group needed to assemble a generator set function. For

example, Group 1 is the Cylinder Head group.

Part Number. The part number identifies an individual

assembly, subassembly, component, or accessory kit.

IllustrationsIllustrations (or exploded-view drawings) best

representing the widest range of variations accompany

most groups in thismanual. Illustrations do not depict all

details and may not show all parts. Do not substitute

illustrations for assembly or disassembly.

How to Find Part NumbersUse the following steps to locate a service replacement

part.

1. Identify the group most likely to include theservice part number.

2. Page forward to locate the group identified instep 1 or find the appropriate page in the Table ofContents.

3. Find the part on the illustration and note the itemnumber of the part or find the part description inthe parts list.

TP-6742 4/104

1--2: Starter

38050322

1

2

Item Part No. Description Qty.

1 GM16178 Starter 12 GM16190 Bolt, starter 2

TP-6742 4/10 5

1--3: Fan Spacer

38030614

1

2

3

Items not shown: 4

Item Part No. Description Qty.

1 GM75123 Spacer, Fan Lightweight 12 GM61733 Washer 43 # Bolt, 5/16-24 x 5 HxHD Gr5 44 GM75195 Washer, Flat 5/16 SAE 16

# Common hardware; procure locally.

TP-6742 4/106

1--5: Flywheel Adapter

38030121

2

1

Item Part No. Description Qty.

1 GM75115 Adapter 12 # Bolt, 3/8-16 x 2 Skt Hd Gr8 4

# Common hardware; procure locally.

TP-6742 4/10 7

1--6: Flywheel/Housing

38030260

1

2

34

Items not shown: 5, 6

Item Part No. Description Qty.

1 GM75116 Housing, SAE3 12 GM75114 Plate, Cover F/W 13 GM75196 Bolt, 3/8-16 x 1 1/4 SktHd Gr5 43 GM75199 Bolt, 3/8-16 x 2 1/4 SktHd 24 GM16189 Plate, starter 15 # Bolt, 5/8-18 x 1 HxHd Zinc 16 # Bolt, 1/4-20x3/8 Flange Hd Ser 8

# Common hardware; procure locally.

TP-6742 4/108

1--7: Exhaust/Intake Manifold

38030832

1

2

3

4

5

6

78

9

10

11

12

13

14

15

16

Items not shown: 17, 18, 19, 20, 2110

Item Part No. Description Qty.

1 GM69517 Bolt, 5/16-18 x 3/4 skt hd, gr. 5 62 GM75195 Washer, Flat 5/16 SAE 63 GM75174 Manifold, Intake Upper 1/2 14 GM75175 Gasket, Manifold 25 GM42579 Hose, fuel 3/8 in. 16 GM38928 Fitting, intake manifold vac 17 GM39442 Gasket, intake manifold 18 GM75177 Intake Manifold, Lower 1/2 19 GM75201 Bolt, 3/8-16 x 1 Skt Hd Gr 8 4

10 GM75205 Washer, Belleville 3/8” 811 GM75200 Stud, 3/8-16x1 3/8 All Thread 212 GM25974 Nut, 3/8-16 213 GM75176 Exhaust Manifold, Rear Outlet 114 GM28932 Gasket, exhaust 115 # Bolt, 3/8-16 x 1 1/4 HxHd Gr 5 316 GM75181 Elbow, Exhaust w/Flange 117 GM38939 Fitting, 3/8 MPT Plug, Hex 118 GM75130 Heat Shield 119 GM60356 Plug, Y-pipe exhaust 119 GM67304 Oxygen Sensor Plug 120 # Washer,Flat 3/8 Hardened Grl9 221 # Bolt, 1/4-20x1/2 Flange Hd Ser 5

# Common hardware; procure locally.

TP-6742 4/10 9

1--11: Electrical

38030968

1

2

3

4

5

6

Items not shown: 7, 8, 9, 10, 11, 12, 13, 14, 15, 16

Item Part No. Description Qty.

1 GM72292 Sensor, O2 12 GM75145 Bracket, Lifting Eye 13 GM75137 Harness, Stationary, IEPR 14 GM29604 Isolator, relay box 25 GM72303 Sender, oil pressure 16 GM29608 Sensor, coolant 17 GM75211 Fitting, Oil Pressure 18 GM75103 Nut, Flange 1/4-20 Serrated 29 GM29582 Plug, brass 1/8 in. NPT 1

10 GM39455 Clamp, 7/8 steel tube 111 GM25974 Nut, 3/8-16 212 # Plug, 1/2” NPT, Steel 213 # Washer, Star 3/8 114 # Bolt, 1/4-20x1/2 Flange Hd Ser 215 # Bolt, 3/8-16x5/8 Flange Hd Ser 116 # Bolt, M10-1.50 X 15 Flg Hd Ser 1

# Common hardware; procure locally.

TP-6742 4/1010

1--13: Fuel System

38030482

1

2

4

5

6

7

10

1112

15

16

Items not shown: 3, 8, 9, 13, 14, 17, 18, 19, 20, 21,

22, 23, 24, 25, 26, 27, 28

Item Part No. Description Qty.

1 GM39222 Throttle body, Bosch 40 mm 12 GM28360 Gasket, TB 13 GM75127 O-ring, -134 Buna-N, UL, 40mm 14 GM75141 Mixer 15 GM75213 I-EPR 15 GM72583 I-EPR, Dual Fuel 16 GM69508 Adapter, EPR, 3/4 NPT 17 GM75140 Adapter, E100 Mixer to Bosch40 18 GM42579 Hose, fuel 3/8 in. 19 GM75162 Seal, Quad -134 Buna-N, UL

40mm2

10 GM39227 Sensor, T-Map 111 GM75192 Bolt, M6-1.0x25 SktHd 412 GM28896 Valve, PCV 113 GM75111 Elbow, Vent (Valve Cover) 114 GM39416 Grommet, 3.0L valve cover 115 GM75206 Bolt, M6 X 1.0 x 85mm SKT HD 416 GM69524 Bolt, M4 x .70 x 16 sht hd 417 GM69488 Clamp, hose 3/8 (spring type) 218 GM75131 Clamp, Hose 7/8”OD 119 GM69490 Adapter, barb 5/8 to 3/8 nylon 120 GM69492 Tube, 0.625 ID x 3 in. 121 GM75158 Nipple, Ext Oil Press Switch 122 GM28963 Washer, lock M6 423 # Bolt 1/4-20x5/8 Flange Hd Ser 124 GM75219 Grommet 125 GM75151 Screw, Tabulated M4 X 12 226 GM72323 Stud, M5-.80 x 25 427 GM72324 Nut, M5-.80 flange 428 GM69487 Fitting, 1/8 NPT x 3/8 90 deg.

Elbow nylon1

# Common hardware; procure locally.

TP-6742 4/10 11

1--14: Dress Kit

38031504

1

2

3

4

56

Items not shown: 8, 9, 10, 11, 12, 13

7

Item Part No. Description Qty.

1 GM38996 Outlet, water 12 GM16537 Thermostat, engine cooling 13 GM16536 Gasket, water outlet 14 GM75208 Pulley 15 GM16703 Filter, oil 16 GM22171 Spark plug 47 GM75113 Lifting Eye, Rear 18 GM16116 Adapter, freeze plug 1/2” NPT 29 GM16118 Plug, 1/2” NPT brass 2

10 # Bolt, 5/16-24 x 3/4 Hx Hd Grd5 411 # Washer,Flat 5/16 Hardened Grl9 412 # Bolt, 3/8-16x1 Flange Hd Ser 113 GM75220 Oil Pressure Fitting 1

# Common hardware; procure locally.

TP-6742 4/1012

1--15: Alternator

38030336

1

2

3

4

5

Items not shown: 6, 7, 8, 9, 10, 11,

12, 13, 14, 15, 16

Item Part No. Description Qty.

1 GM39425 Strap, alternator 12 GM39426 Alternator, 7SI 13 GM75124 Bracket, Alternator 14 GM39427 Sleeve, alternator (spacer) 15 GM75112 Belt, Alternator 16 GM23738 Bolt, head head, M8-1.25 x 30 17 GM75194 Washer, Flat 5/16 USS 18 GM61733 Washer 29 # Bolt, 5/16-18 x 1 Hx Hd Grde 5 1

10 # Bolt, 3/8-16 x 1 Hx Hd Grade 5 211 # Bolt, 3/8-16 x 1 1/4 HxHd Gr 5 112 GM69516 Washer, 3/8 413 GM24190 Washer, flat 3/8 SAE 214 # Nut, 3/8-24 Flange Serrated 115 # Bolt, 3/8-24 x 4 Hx Hd Grade 5 116 # Washer,Flat 3/8 Hardened Grl9 2

# Common hardware; procure locally.

TP-6742 4/10 13

Notes

TP-6742 4/1014

2--1: Engine Block/Lower End

6742_1

TP-6742 4/10 15

2--1: Engine Block/Lower End

Item Part No. Description Qty. Item Part No. Description Qty.

1 GM38999 Ring kit, piston (standard) 42 GM75270 Piston (w/Pin), Std 43 GM16363 Rod, connecting 44 GM16546 Bolt, connecting rod 85 GM75049 Bearing Kit, Conn Rod Std 45 GM38977 Bearing kit, conn rod .001 US 46 - Not Applicable7 GM16586 Nut, connecting rod 88 GM38892 Bearing, oil pump drive shaft 19 GM75015 Gasket, Water Pump 1

10 - NSS. See 1511 - NSS. See 1512 - NSS. See 1513 GM75105 Cap, Heater Water Outlet 114 GM75000 Clamp (11/16” to 1 5/16”) 115 GM75225 Water Pump (includes gasket) 116 GM75012 Bolt, Water Pump 117 - NSS. Part of 1518 - Not Applicable 119 GM16601 Bolt, water pump cover 320 GM75011 Bolt, Water Pump 221 GM16539 Key, crankshaft balancer 222 - Not Applicable23 - Not Applicable24 GM38908 Gear, camshaft 125 GM38978 Plate kit, camshaft 126 - Not Applicable 127 GM38982 Bearing, camshaft 328 GM75002 Camshaft (Incl. 21, 26) 129 GM19023 Valve, oil filter bypass 130 GM16547 Pin, cylinder head locator 831 GM18892 Fitting, oil filter 132 GM38968 Bearing kit, crankshaft

(#1, 2, 3, 4, standard)4

32 GM38969 Bearing kit, crankshaft(#1, 2, 3, 4, .001 US)

4

32 GM38967 Bearing kit, crankshaft(#5, standard)

1

32 GM38945 Bearing kit, crankshaft(#5, .001 US)

1

33 GM16539 Key, crankshaft balancer 134 GM38955 Seal, Front Crankshaft Oil

(Timing Gear Cover)1

35 GM38905 Gear, crankshaft 136 GM75099 Gasket, Front Cover 137 GM38930 Cover, engine front 137 GM38974 Sealer, Engine Front Cover AR38 - NSS - Part of 4139 - NSS - Part of 4140 - NSS - Part of 4141 GM75004 Balancer, Crankshaft 142 - Not Applicable43 - Not Applicable44 - Not Applicable45 GM38973 Nut, oil pan AR46 - Not Applicable47 GM16601 Bolt, water pump cover AR48 GM38926 Plug, oil pan drain 149 GM38988 Gasket, oil pan drain 150 GM39003 Pan, oil 1

51 GM16528 Bolt, valve lifter guide retainer 1252 - NSS - Part of 6353 - NSS - Part of 6354 - NSS - Part of 6355 - NSS - Part of 6356 - NSS - Part of 6357 - NSS - Part of 6358 - NSS - Part of 6359 GM16594 Bolt, camshaft sprocket 360 - NSS - Part of 3761 GM75101 Gasket, Oil Pan 162 GM16595 Bolt, sprk plg wire retainer brckt 663 GM38989 Pump, oil 164 GM38924 Nozzle 165 GM38927 Bracket, oil pump screen 166 GM75261 Crankshaft, Engine 167 GM38938 Bolt, oil pmp scrn brckt AR68 - Not Applicable69 - Not Applicable70 - Not Applicable71 GM38909 Screen, oil pump 172 GM38923 Bolt, crankshaft bearing cap 1073 - Cap, Crankshaft Bearing - NSS74 GM16599 Pin, crankshft rr oil seal locator 175 GM38985 Housing, crankshaft rear oil seal 176 GM38994 Bolt, crankshaft rear oil seal hsg AR77 GM38993 Bolt, crankshaft rear oil seal hsg AR78 GM38981 Gasket, crkshft rear oil seal hsg 179 - Not Applicable80 GM16502 Stud, crnkshft rr oil seal retainer 281 GM38946 Seal, crankshaft rear oil 182 GM75008 Ring Gear, Flywheel - Part of 87 183 GM74995 Washer, Flywheel 684 GM38896 Bolt, flywheel 685 GM38917 Bolt, valve push rod cover 486 - Not Applicable87 GM39002 Flywheel 188 GM39007 Cover, valve push rod 189 GM38899 Pin 290 GM75048 Sealer, Valve Push Rod Cover AR91 GM16510 Plug, 3/8-18 x .42 192 GM74970 Engine, 3.0L (181 CID) 193 GM16397 Plug, camshaft rear bearing hole AR94 GM38919 Plug, engine block core hole AR95 - Not Applicable96 GM38922 Plug, engine block oil galley 197 GM75260 Tube, Oil Level Indicator

w/Bracket1

98 GM75094 Indicator, Oil Level 199 - Not Applicable

100 GM38976 Sealer, valve push rod cover AR101 GM38893 Stud, valve push rod cover 1102 GM38895 Nut, valve push rod cover 1103 GM38903 Washer, valve push rod cover 3107 GM75064 Sensor, Cr/Shf Posn 1107 GM75040 Bolt, Cr/Shf Posn Sen 1110 GM75273 Gasket, fuel pump 1111 GM75262 Cover, fuel pump 1112 GM16575 Washer, camshaft sprocket 3113 GM16594 Bolt, camshaft sprocket 3

NSS: Not Serviced Separately.

TP-6742 4/1016

2--2: Engine Head/Upper End

6742_2

TP-6742 4/10 17

2--2: Engine Head/Upper End

Item Part No. Description Qty. Item Part No. Description Qty.

1 GM75016 Cap, Oil Fill 12 GM16595 Bolt, spark plg wire retainer brkt 63 GM38925 Reinforcement, vlv rckr arm cvr AR4 GM38907 Cover, valve rocker arm 15 GM75098 Gasket, valve rocker arm cover AR6 GM38936 Bolt 37 - Outlet, water (See Group 1-4) 18 - Thermostat, engine cooling

(See Group 1-4)1

9 - Gasket, water outlet(See Group 1-4)

1

10 GM75269 Housing, eng cooling tstat 111 GM38936 Bolt 312 GM38952 Bolt, cylinder head AR13 GM38920 Plug, cylinder head core hole 214 - Nut (See Group 1-7) 815 - Stud (See Group 1-7) 216 - Washer (See Group 1-7) AR17 - Bolt, exhaust manifold

(See Group 1-7)3

18 - Stud, intake man to cyl. head(See Group 1-7)

1

19 - Bolt, intake manifold(See Group 1-7)

AR

20 - Manifold, intake (See Group 1-7) 121 - Fitting, intke manifold vacuum

(See Group 1-7)1

22 - Not Applicable23 - Not Applicable24 - Gasket, exhaust manifold (See

Group 1-7)1

25 - Not Applicable26 - Not Applicable27 - Manifold, exhaust

(See Group 1-7)1

28 - Stud, exhaust pipe(See Group 1-7)

2

29 - Clamp, int/exh manifold(See Group 1-7)

4

30 - Gasket, intake manifold(See Group 1-7)

1

31 GM75017 Gasket, engine cooling tstat 132 GM16585 Plug, engine block core hole AR33 GM16407 Bolt, distributor cap 234 GM38963 Cap, distributor 135 GM38956 Rotor, distributor 136 GM38957 Shaft, distributor 137 GM38965 Retainer, dist ignition pick up coil 138 GM38964 Seal, dist housing oil (o-ring) 139 - Not Applicable 140 GM16543 Pin, distributor ignition pick up

lock - Part of 51

41 GM16418 Module, dist ignition control 1

42 GM16406 Bolt, distributor 243 GM38962 Pole piece, distributor pick up 144 GM16413 Coil, distributor pickup 145 GM38959 Gear, distributor shaft 146 GM38935 Pin, distributor gear 147 GM38995 Gasket, cylinder head 148 - Spark plug (See Group 1-14) 449 GM75268 Valve, exhaust 450 - NSS - Part of 6851 GM75267 Valve, Intake 452 GM38934 Bracket, engine lift front 153 GM38942 Bolt, engine lift front bracket 854 GM38897 Distributor 155 GM38949 Gasket, distributor 156 GM38913 Washer, distributor 157 - Not Applicable58 GM38894 Clamp, distributor 159 GM16425 Wire, ignition coil 160 GM38936 Bolt 361 GM16597 Bolt, ignition coil 262 - Not Applicable63 GM75001 Retainer, spark plug wire AR64 GM38898 Coil, ignition 165 GM39011 Wire, ignition coil 166 GM75259 Harness, spark plug wire 167 GM38931 Lifter, valve 868 GM39001 Rod, valve push 869 GM38918 Stud, vlv rocker arm ball

(.003 in. OS)8

69 GM16584 Stud, valve rocker arm ball 870 GM38953 Seal, valve stem oil (o-ring type) 871 GM75266 Head, cylinder 172 GM75096 Spring, valve 872 GM75274 Spring, valve

(ident. white stripe)8

73 GM38944 Cap, valve spring 874 GM16342 Shield, valve stem oil 1275 GM38932 Arm kit, valve rocker (w/ball) 876 GM39009 Ball, valve rocker arm 877 GM16493 Nut, valve rocker arm 878 GM16529 Key, valve stem 1679 GM16501 Rotator, valve 480 - Not Applicable81 - Not Applicable82 - Not Applicable83 - Not Applicable84 - Not Applicable85 - Not Applicable86 - Not Applicable87 GM38893 Stud, valve push rod cover 188 GM38895 Nut, valve push rod cover 196 GM75092 Cap, PCV tube 1

108 GM75014 Sensor, engine coolant temp 1

NSS: Not Serviced Separately.

� 2010 by Kohler Co. All rights reserved.

TP-6742 4/10

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